Delrin rollers for factory winch

[Colibri]

Hey all, I just purchased a synthetic line for my winch and I'm wanting to swap my stock chewed up steel rollers for some oh so smooth delrin pieces. There's a low volume/prototype friendly plastics machining company in town near me that I'm going to contact to make them as they're not available for our application already. Is there any interest from others for this? I would imagine that unit price would be less the more pieces are produced. I'm going to break out the tape measure and dial calipers and get on the horn with them probably next week. If there are any takers post up here. I'm doing it for myself for sure but saw an opportunity to give back to the community on this one, so maybe we can get a group buy going or something?

[cruz]

I'm still running steel wire rope but I know I'll be changing somewhere down the road, if we can get them cheap enough I'd get a set and throw 'em on the shelf for later. So as of right now, count me in, depending on the final cost.

[nts007]

I bought a set of delrin rollers years ago. The closest size I could find. They never worked. That was in 08 though. I ended up just wrapping my steel rollers in electrical tape. They weren't gouged though

[SnakeEyes]

Just get brand newer steel rollers and give them a polish. It will make them super smooth and work well with synthetic line. That's what I do with my atv for years now

[Colibri]

When I last spoke to the parts department I was told 3rd gen fair lead rollers were on indefinite back order so that's a no go. Figure if I have to get something made it might just as well be exactly right for the given application. I thought this would have garnered more interest, weird.

[RAM4ROKS]

If there is a possibility of 4th gen rollers, I would be 100% down to buy some!!!!

[Colibri]

Just need dimensions from you and I'll ask about it when I speak to them. Called today and left a message so hopefully we'll see soon

[Cactus Red]

I'm a Manufacturing Engineer/CNC programmer for a 45000 sq/ft shop. So, I can comment on building these with at least some knowledge.

It's cost - a hole that dia and that deep, even in plastic, is expensive. A Kennametal drill and insert used for production of something like that is about $500.00, and machine large enough to do that is about $120.00 an hour shop rate. Material is sold by the foot, figure 3' per set of four as an estimate, at $10.00 a foot, that's $30.00 in material. IF the material is exactly the right size, It would take less than a minute to drill the hole, face and break the end. On a bar feeding lathe, then it would be chamfered and cut off. If on one of our smaller machines, it would have to be flipped, faced and break the corners. If it had to be OD turned to size, that adds time too.

So, figure in our profit margin, (and since we're an AS-9100 shop, the required $300.00 in paper work we can't get out of), 10 sets would take 30' of material, our fixed setup and inspection charges of $500.00, an hour minimum machine time, and shipping, all of a sudden those rollers are spendy for ten sets...

[verdesardog]

I bet someone with a CNC machine shop could turn out aluminum hawse fairleads specifically for PW's at a cost effective price.......

[Cactus Red]

Same as above, but more expensive material, and time wise, it would take longer.

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[fbenross]

I have never had to use my winch. I just check it before I head out to the desert. But I did change to synthetic for the big weight savings.

[Colibri]

Ours being an under served niche market does get old at times doesn't it lol. I really appreciate your insight on this cactus. I am undeterred though. there's got to be a reasonable way to make this happen.

[Ducky's Dad]

Doesn't Warn offer a set of rollers that will work? Won't be a Dodge P/N and Warn will probably refer you back to a Dodge dealer, but I'd look at the M12000 and M15000 parts lists.

[Low_Sky]

Doesn't Warn offer a set of rollers that will work? Won't be a Dodge P/N and Warn will probably refer you back to a Dodge dealer, but I'd look at the M12000 and M15000 parts lists.

I wouldn't be surprised if you're right, and the rollers are standard Warn parts on a bracket made specially for the Power Wagon. It doesn't make sense to design new rollers when their location is the only thing that needs to move, for the reasons that Cactus Red described.

[leo72987]

I have stocked up on the factory rollers but that would be interesting if the standard warn units worked. The part number is 61956.

[Cactus Red]

Our cradle is different than any I've seen, both in length and roller placement. It's greatly superior to a standard roller fairlead.

Dennis Miller "You can't order black coffee anymore. It's un-creamed..."

[leo72987]

Opps cactus already answered haha o well was worth a shot

[nts007]

The delrin rollers I bought were the ones made for warns cradle for the m15000. They seemed closest. Nope. Too short by 1.5" on the horizontal and almost 3/4" vertical.

[2wagons1driveway]

After watching ken (kenadian) winch with full synth winch line it's Deffinately a mod I would like to do....


Sent from that big land mass the rest of the world hates

[Cactus Red]

It's not a necessity. I've used the same synthetic rope since '09. I polished the rollers to remove any burrs, and it's been fine.

Dennis Miller "You can't order black coffee anymore. It's un-creamed..."

[nts007]

I apologize. Earlier I was going off of memory that apparently was wishful thinking. The long rollers were way to short and the short ones needed to get cut down. These were the ones recommended for the warn m15000. They obviously don't work

[olyelr]

I have never even seen the winch setup on a power wagon, but wouldnt a typical hawse fairleed work?

[olyelr]

Like these https://www.warn.com/truck/accessories/ ... lead.shtml

[FirerescuePW]

You could use one, but you would have to modify the mounting bracket or make an adapter to secure the hawse fairlead to the OEM cradle. The OEM rollers are built into the cradle.

[Colibri]

An adapter to use a hawse fairlead is starting to look like a better option for me, the fab shop I use has Cnc plasma cutting and bending capability and a little plate work is far more economical than machining seems to be. I'll have him save the files in case anyone else with a 3rd gen wants one. Truck will be in his shop soonish, just have to finish the axle swap first. I'll update with pics as things start to happen.